FU(STI)-17
Intake Manifold
FUEL INJECTION (FUEL SYSTEMS)
3. Intake Manifold
A: REMOVAL
1) Remove the V-belt covers.
2) Collect the refrigerant from A/C system. <Ref. to
AC-26, PROCEDURE, Refrigerant Recovery Pro-
cedure.>
3) Release the fuel pressure. <Ref. to FU(STI)-64,
RELEASING OF FUEL PRESSURE, PROCE-
DURE, Fuel.>
4) Disconnect the ground cable from battery.
5) Open the fuel filler lid and remove the fuel filler
cap.
NOTE:
This operation is required to release the inner pres-
sure of the fuel tank.
6) Lift up the vehicle.
7) Remove the under cover. <Ref. to EI-21, RE-
MOVAL, Front Under Cover.>
8) Drain approximately 3.0 L (3.2 US qt, 2.6 Imp qt)
of coolant. <Ref. to CO(STI)-13, DRAINING OF
ENGINE COOLANT, REPLACEMENT, Engine
Coolant.>
9) Remove the air intake duct. <Ref. to IN(STI)-11,
REMOVAL, Air Intake Duct.>
10) Remove the chamber assembly. <Ref. to
IN(STI)-22, REMOVAL, Chamber Assembly.>
11) Remove the intercooler. <Ref. to IN(STI)-13,
REMOVAL, Intercooler.>
12) Remove the air intake boot.
13) Remove the air by-pass valve. <Ref. to
IN(STI)-20, REMOVAL, Air By-pass Valve.>
14) Remove the generator. <Ref. to SC(STI)-15,
REMOVAL, Generator.>
15) Remove the coolant filler tank. <Ref. to
CO(STI)-28, REMOVAL, Coolant Filler Tank.>
16) Disconnect the A/C pressure hoses from A/C
compressor. <Ref. to AC-63, REMOVAL, Hose and
Pipe.>
17) Disconnect the engine coolant hose from throt-
tle body.
18) Disconnect the brake booster vacuum hose (A)
and pressure regulator vacuum hose (B) from the
intake manifold.
19) Disconnect the connector from the PCV hose
assembly A.
FU-03487
IN-03564
FU-05761
ME-05007
E N G
(A)
(B)
FU-08341
15WRX_STI_US_EN.book 17 ペー   
FU(STI)-18
Intake Manifold
FUEL INJECTION (FUEL SYSTEMS)
20) Remove the PCV hose assembly A from clip
(A), and remove the vacuum hose from clip (B).
21) Disconnect the vacuum hose (A) and the con-
nector (B) from the PCV hose assembly B.
22) Disconnect the air control hose (A) from the
waste gate actuator, and loosen the clamp which
holds the intake duct to the turbocharger.
23) Remove the engine coolant hose from the wa-
ter tank pipe.
24) Remove the engine harness from clip (A).
25) Disconnect the bulkhead harness connectors
from the engine harness connectors.
26) Lift the claw (A) and remove the engine har-
ness connector from the engine harness bracket.
27) Disconnect the connector (A) from the engine
coolant temperature sensor, connector (B) from the
oil pressure switch, and connector (C) from the
crankshaft position sensor.
28) Disconnect the connector from power steering
pump switch.
FU-08342
(A)
(B)
(A)
(B)
FU-08343
FU-04384
(A)
FU-06569
FU-06570
(A)
FU-08327
(A)
(C)
(A)
(B)
FU-05725
FU-04598
15WRX_STI_US_EN.book 18 ペー   
FU(STI)-19
Intake Manifold
FUEL INJECTION (FUEL SYSTEMS)
29) Disconnect the connector from the knock sen-
sor.
30) Disconnect the connector from the secondary
air combination valve.
31) Disconnect the connector from the intake cam-
shaft position sensor.
32) Disconnect the connector from the intake oil
flow control solenoid valve.
33) Lift up the vehicle.
34) Remove the engine harness cover. (right side
only.)
35) Remove the clip holding the engine harness.
(Left side only)
FU-03492
FU-03493
FU-04385
FU-03495
FU-03616
FU-08481
15WRX_STI_US_EN.book 19 ペー   
FU(STI)-20
Intake Manifold
FUEL INJECTION (FUEL SYSTEMS)
36) Disconnect connector (A) from the exhaust
camshaft position sensor, connector (B) from the
exhaust oil flow control solenoid valve, and connec-
tor (C) from the ignition coil.
37) Lower the vehicle.
38) Remove the clip (A) which hold the engine har-
ness to the rocker cover RH.
39) Remove the bolts that secure the air duct to the
rocker cover LH, and remove the engine harness.
40) Disconnect the fuel delivery hose, fuel return
hose and evaporation hose.
CAUTION:
Be careful not to spill fuel.
Catch the fuel from hoses using a container
or cloth.
(1) Set the ST to the fuel pipe.
ST 42099AE000 QUICK CONNECTOR RE-
LEASE
(2) Disconnect the quick connector of the fuel
delivery hose and fuel return hose by pushing
the ST in the direction of the arrow.
(3) Remove the clip and disconnect the evapo-
ration hose from the fuel pipe.
41) Remove the intake manifold from cylinder
head.
FU-05746
(B)
(C)
(C)
(A)
(C)
(C)
(A)
(B)
FU-03581
(A)
FU-06573
(A) Fuel delivery hose
(B) Fuel return hose
(C) Evaporation hose
ME-05008
(A)
(B)
ST
(C)
FU-06574
15WRX_STI_US_EN.book 20 ペー   
FU(STI)-21
Intake Manifold
FUEL INJECTION (FUEL SYSTEMS)
B: INSTALLATION
1) Install the intake manifold onto cylinder heads.
NOTE:
Use a new gasket.
Tightening torque:
25 N·m (2.5 kgf-m, 18.4 ft-lb)
2) Connect the fuel delivery hose, fuel return hose,
and evaporation hose.
3) Fix the engine harness to the rocker cover LH
with the air duct.
Tightening torque:
6.4 N·m (0.7 kgf-m, 4.7 ft-lb)
4) Fix the engine harness to the rocker cover RH
with clips (A).
5) Lift up the vehicle.
6) Connect connector (A) to the exhaust camshaft
position sensor, connector (B) to the exhaust oil
flow control solenoid valve, connector (C) to the ig-
nition coil.
(A) Fuel delivery hose
(B) Fuel return hose
(C) Evaporation hose
FU-06574
FU-05783
(A)
(B)
(C)
FU-06573
FU-03581
(A)
FU-05746
(B)
(C)
(C)
(A)
(C)
(C)
(A)
(B)
15WRX_STI_US_EN.book 21 ペー   
FU(STI)-22
Intake Manifold
FUEL INJECTION (FUEL SYSTEMS)
7) Install the engine harness cover. (right side
only.)
Tightening torque:
5 N·m (0.5 kgf-m, 3.7 ft-lb)
8) Install the clip securing the engine harness. (Left
side only)
9) Lower the vehicle.
10) Connect the connector to the intake oil flow
control solenoid valve.
11) Connect the connector to the intake camshaft
position sensor.
12) Connect the connector to the secondary air
combination valve.
13) Connect the connector to the knock sensor.
FU-03616
FU-08481
FU-03495
FU-04385
FU-03493
FU-03492
15WRX_STI_US_EN.book 22 ペー   
FU(STI)-23
Intake Manifold
FUEL INJECTION (FUEL SYSTEMS)
14) Connect the connector to the power steering
pump switch.
15) Connect the connector (A) to the engine cool-
ant temperature sensor, connector (B) to the oil
pressure switch, and the connector (C) to the
crankshaft position sensor.
16) Install the engine harness connector to engine
harness bracket, then connect the bulkhead har-
ness connector to the engine harness connector.
17) Install the engine harness to clip (A).
18) Install the engine coolant hose to the water
tank pipe.
19) Connect the air control hose (A) to the waste-
gate actuator, and install the turbocharger to the in-
take duct.
Tightening torque:
3 N·m (0.3 kgf-m, 2.2 ft-lb)
20) Connect the vacuum hose (A) and connector
(B) to the PCV hose assembly B.
21) Install the vacuum hose to clip (B), and install
the PCV hose assembly A to clip (A).
FU-04598
(C)
(A)
(B)
FU-05725
FU-08417
FU-06570
(A)
FU-06569
FU-04384
(A)
(A)
(B)
FU-08343
FU-08342
(A)
(B)
15WRX_STI_US_EN.book 23 ペー   
FU(STI)-24
Intake Manifold
FUEL INJECTION (FUEL SYSTEMS)
22) Connect the connector to the PCV hose as-
sembly A.
23) Connect the brake booster vacuum hose (A)
and pressure regulator vacuum hose (B) to the in-
take manifold.
24) Connect the engine coolant hoses to throttle
body.
25) Install the A/C pressure hoses to A/C compres-
sor. <Ref. to AC-67, INSTALLATION, Hose and
Pipe.>
26) Install the coolant filler tank. <Ref. to CO(STI)-
28, INSTALLATION, Coolant Filler Tank.>
27) Install the generator. <Ref. to SC(STI)-15, IN-
STALLATION, Generator.>
28) Install the air by-pass valve. <Ref. to IN(STI)-
20, INSTALLATION, Air By-pass Valve.>
29) Install the air intake boot.
Tightening torque:
2.5 N·m (0.3 kgf-m, 1.8 ft-lb)
30) Install the intercooler. <Ref. to IN(STI)-14, IN-
STALLATION, Intercooler.>
31) Install the chamber assembly. <Ref. to IN(STI)-
22, INSTALLATION, Chamber Assembly.>
32) Install the air intake duct. <Ref. to IN(STI)-11,
INSTALLATION, Air Intake Duct.>
33) Connect the battery ground terminal.
34) Lift up the vehicle.
35) Install the under cover. <Ref. to EI-22, INSTAL-
LATION, Front Under Cover.>
36) Lower the vehicle.
37) Install the V-belt cover.
Tightening torque:
13 N·m (1.3 kgf-m, 9.6 ft-lb)
38) Fill engine coolant. <Ref. to CO(STI)-13, FILL-
ING OF ENGINE COOLANT, REPLACEMENT,
Engine Coolant.>
39) Charge the A/C system with refrigerant. <Ref.
to AC-27, PROCEDURE, Refrigerant Charging
Procedure.>
FU-08341
ME-05007
E N G
(A)
(B)
FU-05761
IN-03564
FU-03487
15WRX_STI_US_EN.book 24 ペー   
FU(STI)-25
Intake Manifold
FUEL INJECTION (FUEL SYSTEMS)
C: DISASSEMBLY
1) Remove clamp (A) holding the fuel pipe protec-
tor RH to the engine harness, and remove the fuel
pipe protector RH.
2) Remove the fuel pipe protector LH.
3) Remove the connector from the intake duct.
4) Remove the connector from the PCV hose as-
sembly.
5) Remove purge control solenoid valve 1 (A) and
purge control solenoid valve 2 (B).
6) Disconnect the connector (A) from the waste-
gate control solenoid valve, and disconnect the
vacuum hose (B) from the intake duct.
7) Remove the solenoid valve bracket together with
the wastegate control solenoid valve.
8) Remove the engine ground terminals from the
intake manifold.
FU-06575
(A)
FU-06591
FU-05921
FU-06576
FU-06577
(A)
(B)
FU-06578
(A)
(B)
FU-06579
FU-03588
15WRX_STI_US_EN.book 25 ペー   
FU(STI)-26
Intake Manifold
FUEL INJECTION (FUEL SYSTEMS)
9) Disconnect the connector (A) from the throttle
position sensor, and the connector (B) from the
manifold pressure sensor.
10) Remove clip (A) holding the engine harness
and vacuum hose, clip (B) holding the engine har-
ness to the engine harness stay, and the bolt hold-
ing the engine harness to the intake manifold.
11) Remove the throttle body from the intake man-
ifold.
12) Remove the harness band (A) which holds the
engine harness to the fuel injector pipe.
RH side
•LH side
13) Disconnect the connector from fuel injector.
14) Disconnect the connector from the tumble gen-
erator valve assembly.
15) Remove the bolts which hold fuel injector pipe.
•RH side
FU-05918
(B)
(A)
FU-03565
(A)
(B)
FU-05692
FU-05919
(A)
FU-05920
(A)
FU-03508
FU-04604
FU-03512
15WRX_STI_US_EN.book 26 ペー   
FU(STI)-27
Intake Manifold
FUEL INJECTION (FUEL SYSTEMS)
•LH side
16) Remove the fuel injector.
17) Remove the harness brackets holding the en-
gine harness to the intake manifold, and remove
the engine harness.
18) Loosen the clamp holding the RH side fuel
hose to the fuel injector pipe RH, and remove the
fuel injector pipe RH.
19) Loosen the clamp holding the LH side fuel hose
to the fuel injector pipe LH, and remove the fuel in-
jector pipe LH.
20) Remove the bolts holding the fuel pipe assem-
bly to the intake manifold, and remove the fuel pipe
assembly.
21) Remove the intake duct from intake manifold.
FU-03594
FU-03595
FU-03513
FU-03567
FU-04605
FU-04606
FU-00051
FU-06580
15WRX_STI_US_EN.book 27 ペー   
FU(STI)-28
Intake Manifold
FUEL INJECTION (FUEL SYSTEMS)
22) Remove the tumble generator valve assembly
from the intake manifold.
23) Remove the nipple from the intake manifold.
D: ASSEMBLY
1) Apply liquid gasket to the nipple threads, and in-
stall the nipple to the intake manifold.
Liquid gasket:
THREE BOND 1105 (Part No. 004403010) or
equivalent
Tightening torque:
T1: 17 N·m (1.7 kgf-m, 12.5 ft-lb)
T2: 25 N·m (2.5 kgf-m, 18.4 ft-lb)
2) Install the tumble generator valve assembly onto
intake manifold.
NOTE:
Use a new gasket.
Tightening torque:
8.3 N·m (0.8 kgf-m, 6.1 ft-lb)
3) Install the air intake duct to the intake manifold.
Tightening torque:
17 N·m (1.7 kgf-m, 12.5 ft-lb)
4) Install the fuel pipe assembly to the intake man-
ifold.
Tightening torque:
6.4 N·m (0.7 kgf-m, 4.7 ft-lb)
FU-03603
FU-05787
FU-05788
T1
T2
FU-03603
FU-06580
FU-00051
15WRX_STI_US_EN.book 28 ペー   
FU(STI)-29
Intake Manifold
FUEL INJECTION (FUEL SYSTEMS)
5) Install the fuel injector pipe LH and connect the
LH side fuel hose to the fuel injector pipe LH. <Ref.
to FU(STI)-99, CONNECTING FUEL DELIVERY
HOSE, FUEL RETURN HOSE AND FUEL HOSE,
INSTALLATION, Fuel Delivery, Return and Evapo-
ration Lines.>
6) Install the fuel injector pipe RH and connect the
RH side fuel hose to the fuel injector pipe RH. <Ref.
to FU(STI)-99, CONNECTING FUEL DELIVERY
HOSE, FUEL RETURN HOSE AND FUEL HOSE,
INSTALLATION, Fuel Delivery, Return and Evapo-
ration Lines.>
7) Install the engine harness to the intake manifold
and attach the harness brackets holding the engine
harness.
Tightening torque:
19 N·m (1.9 kgf-m, 14.0 ft-lb)
8) Install the fuel injector.
NOTE:
Use new O-rings, rubbers and seal rings.
9) Install the bolts which hold fuel injector pipe.
•RH side
Tightening torque:
19 N·m (1.9 kgf-m, 14.0 ft-lb)
•LH side
Tightening torque:
6.4 N·m (0.7 kgf-m, 4.7 ft-lb)
FU-04606
FU-04605
FU-03567
FU-03513
FU-03512
FU-03594
15WRX_STI_US_EN.book 29 ペー   
FU(STI)-30
Intake Manifold
FUEL INJECTION (FUEL SYSTEMS)
Tightening torque:
19 N·m (1.9 kgf-m, 14.0 ft-lb)
10) Connect the connector to the tumble generator
valve assembly.
11) Connect the connectors to the fuel injector.
12) Secure the engine harness to the fuel injector
pipe with the harness band (A).
RH side
•LH side
13) Install the throttle body to the intake manifold.
NOTE:
Use a new gasket.
Tightening torque:
8 N·m (0.8 kgf-m, 5.9 ft-lb)
14) Secure the engine harness and vacuum hose
using the clip (A), and secure the engine harness to
the engine harness stay using the clip (B), and in-
stall the bolt which holds the engine harness to the
intake manifold.
Tightening torque:
19 N·m (1.9 kgf-m,14.0 ft-lb)
FU-03595
FU-04604
FU-03508
FU-05919
(A)
FU-05920
(A)
FU-05692
FU-03565
(A)
(B)
15WRX_STI_US_EN.book 30 ペー   
FU(STI)-31
Intake Manifold
FUEL INJECTION (FUEL SYSTEMS)
15) Connect connector (A) to the throttle position
sensor and connector (B) to the manifold pressure
sensor.
16) Install the engine ground terminal to intake
manifold.
Tightening torque:
19 N·m (1.9 kgf-m, 14.0 ft-lb)
17) Install the solenoid valve bracket together with
the wastegate control solenoid valve.
Tightening torque:
T1: 6.4 N·m (0.7 kgf-m, 4.7 ft-lb)
T2: 19 N·m (1.9 kgf-m, 14.0 ft-lb)
18) Connect the vacuum hose (B) to the intake
duct, then connect the connector (A) to the waste-
gate control solenoid valve.
19) Install purge control solenoid valve 1 and purge
control solenoid valve 2.
NOTE:
Connect the vacuum hose and vacuum control
hose as shown in the figure.
FU-05918
(B)
(A)
FU-03588
FU-06581
T1
T2
(A) Purge control solenoid valve 1
(B) Purge control solenoid valve 2
(a) To intake duct
(b) To intake manifold
(c) To branching pipe fuel pipe
FU-06578
(A)
(B)
(c)
(b)
(a)
(B)
(A)
(c)
FU-04417
15WRX_STI_US_EN.book 31 ペー   
FU(STI)-32
Intake Manifold
FUEL INJECTION (FUEL SYSTEMS)
Tightening torque:
T1: 6.4 N·m (0.7 kgf-m, 4.7 ft-lb)
T2: 19 N·m (1.9 kgf-m, 14.0 ft-lb)
20) Attach the connector to the PCV hose assem-
bly.
21) Install the connector to the intake duct.
22) Install the fuel pipe protector LH.
Tightening torque:
19 N·m (1.9 kgf-m, 14.0 ft-lb)
23) Install the fuel pipe protector RH, and secure
the engine harness to the fuel pipe protector RH
using the clip (A).
Tightening torque:
19 N·m (1.9 kgf-m, 14.0 ft-lb)
E: INSPECTION
1) Check that the intake manifold and fuel pipe
have no deformation, cracks and other damages.
2) Check that the hose has no cracks, damage or
loose part.
FU-06582
T2
T1
FU-06576
FU-05921
FU-06591
FU-06575
(A)
15WRX_STI_US_EN.book 32 ペー